Cable Design Project

Assignments

1. Team Steel assigned 1045 Steel

2. Cable Design

3. Buckle Design

4. Analyze Cable Design within given

Temperature Range

5. Mars Modification

6. Cost to get Project into to Orbit

7. Temperature Issue on Mars

Team Members

• David Rogers

(Dave)

• Michael Roeback

(Mike)

• William Wyant

(Bill)

1

Assignment #1- Design a cable that can

support a 5 ton load using the "Modulus of

Elasticity" numbers for the materials

shown in the Lecture 3 slides.

2

Cable SelectionBased on 10% Elongation

Capability Load Stress in^2

Al 10,000,000 10000 1,000,000 10.0E-3 0.11284

Ti 12,000,000 10000 1,200,000 8.3E-3 0.10301

Copper 15,000,000 10000 1,500,000 6.7E-3 0.09213

Steel 30,000,000 10000 3,000,000 3.3E-3 0.06515 1/8 in

e=l-lo/lo σ=P/Ao

Capability 5 tons 2 2 FALSE 2 To Big Check

Weight 10000 lbs 1 3/4 1.75 FALSE 1 3/4 To Big Check

Length= 25 ft 1 1/2 1.50 FALSE 1 1/2 To Big Check

Cable Length 25 ft 1 1/4 1.25 FALSE 1 1/4 To Big Check

Allowable Stretch 10.00% 1 1.00 FALSE 1 To Big Check

Max. Length 27.5 ft 3/4 0.75 FALSE 3/4 To Big Check

Strain 0.1 1/2 0.500000 FALSE 1/2 To Big Check

7/16 0.437500 FALSE 7/16 To Big Check

3/8 0.375000 FALSE 3/8 To Big Check

5/16 0.312500 FALSE 5/16 To Big Check

1/4 0.250000 FALSE 1/4 To Big Check

3/16 0.187500 FALSE 3/16 To Big Check

1/8 0.125000 TRUE 1/8 To Big Check

1/16 0.062500 FALSE 1/16 Check To Small

1/32 0.031250 FALSE 1/32 Check To Small

1/64 0.015625 FALSE 1/64 Check To Small

Cable size

Best Diameter to use

Fractional/Decimal Conversion Steel

Min. Diameter (in) CSA

3

Assignment #2 - Determine the lateral

stress in the cable design

Courtesy of:

http://www.eng.ox.ac.uk/~kneabz/teaching/seh/Stress1_mt07.pdf

4

How Poisson’s Ratio Transfers from

Strain to Stress

Capability= 5 tons

Weight= 10000 lbs

Length= 25 ft

Cable Length= 25 ft

Allowable Stretch= 10.00%

Max. Length= 27.5 ft

Strain= 0.1

Cable Diameter= 1/8 in

Cable CSA= 12.272E-3 in^2

Cable Stress= 814.873E+3 psi

Poisson's Ratio= 0.30

Laterial Strain= -0.03

Stress/Strain= 8.149E+6 psi

Lateral Stress= -244.462E+3 psi

Stress Ratio= -300.0E-3

• Poisson’s Ratio for Steel is .30

• A direct relation between Axial force

and Lateral force.

•Strain went from 0.01 to -0.03 so Force

went from 10000 flb to -3000 flb.

5

Assignment #3 – Design a buckle with a Cyclic

Life of 100k to be used with the Cable

y = -5517ln(x) + 120714

R² = 0.9928

y = 43000

y = -0.0014x + 45710

R² = 1

000.0E+0

10.0E+3

20.0E+3

30.0E+3

40.0E+3

50.0E+3

60.0E+3

70.0E+3

80.0E+3

1.E+03 10.E+03 100.E+03 1.E+06 10.E+06 100.E+06 1.E+09

Steel Trends

6

1045 Steel 100k Cycle ThresholdCycles psi Mpa at 10^5 Cycles Coeffic. Constant

10.0E+3 69.0E+3 475.738253 57.2E+3 -5517 120714

39.8E+3 63.0E+3 434.3697093 57.2E+3 -5517 120714

100.0E+3 58.0E+3 399.8959228 57.2E+3 -5517 120714

316.2E+3 51.0E+3 351.6326218 57.2E+3 -5517 120714

794.3E+3 45.0E+3 310.2640781 57.2E+3 -5517 120714

1.3E+6 44.0E+3 303.3693208 45.7E+3 -0.0014 45710

2.0E+6 43.0E+3 296.4745635 45.7E+3 -0.0014 45710

3.2E+6 43.0E+3 296.4745635 43.0E+3 43000

10.0E+6 43.0E+3 296.4745635 43.0E+3 43000

100.0E+6 43.0E+3 296.4745635 43.0E+3 43000

199.5E+6 43.0E+3 296.4745635 43.0E+3 43000

Diameter (d) 1/2*d π*r^2 10000/CSA 10000/CSA

Buckle Size (in) Radius ( r ) CSA (in^2) Stress (PSI) Stress (Mpa)

1/16 0.031 3.068E-3 3.259E+6 22.473E+3

1/8 0.063 12.272E-3 814.873E+3 5.618E+3

3/16 0.094 27.612E-3 362.166E+3 2.497E+3

1/4 0.125 49.087E-3 203.718E+3 1.405E+3

5/16 0.156 76.699E-3 130.380E+3 898.937E+0

3/8 0.188 110.447E-3 90.541E+3 624.262E+0

7/16 0.219 150.330E-3 66.520E+3 458.641E+0

1/2 0.250 196.350E-3 50.930E+3 351.147E+0

9/16 0.281 248.505E-3 40.241E+3 277.450E+0

5/8 0.313 306.796E-3 32.595E+3 224.734E+0

11/16 0.344 371.223E-3 26.938E+3 185.731E+0

3/4 0.375 441.786E-3 22.635E+3 156.065E+0 7

Assignment #4 - Temperature Range

-40ºC to 125ºF

8

Original Temperature = 68˚F 20˚C

α (steel) = 0.0000065

Original Length = 300 in 25ft∆L=α*Lo*∆T

ΔL ΔT Tempf ˚C Tempf ˚F

-0.21060 in -108.0 ˚F -40 ˚C -40.0 ˚F

-0.20358 in -104.4 ˚F -38 ˚C -36.4 ˚F

-0.19656 in -100.8 ˚F -36 ˚C -32.8 ˚F

-0.18954 in -97.2 ˚F -34 ˚C -29.2 ˚F

-0.18252 in -93.6 ˚F -32 ˚C -25.6 ˚F

-0.17550 in -90.0 ˚F -30 ˚C -22.0 ˚F

-0.16848 in -86.4 ˚F -28 ˚C -18.4 ˚F

-0.16146 in -82.8 ˚F -26 ˚C -14.8 ˚F

-0.15444 in -79.2 ˚F -24 ˚C -11.2 ˚F

-0.14742 in -75.6 ˚F -22 ˚C -7.6 ˚F

-0.14040 in -72.0 ˚F -20 ˚C -4.0 ˚F

-0.13338 in -68.4 ˚F -18 ˚C -0.4 ˚F

-0.12636 in -64.8 ˚F -16 ˚C 3.2 ˚F

-0.11934 in -61.2 ˚F -14 ˚C 6.8 ˚F

-0.11232 in -57.6 ˚F -12 ˚C 10.4 ˚F

-0.10530 in -54.0 ˚F -10 ˚C 14.0 ˚F

-0.09828 in -50.4 ˚F -8 ˚C 17.6 ˚F

-0.09126 in -46.8 ˚F -6 ˚C 21.2 ˚F

-0.08424 in -43.2 ˚F -4 ˚C 24.8 ˚F

-0.07722 in -39.6 ˚F -2 ˚C 28.4 ˚F

-0.07020 in -36.0 ˚F 0 ˚C 32.0 ˚F

-0.06318 in -32.4 ˚F 2 ˚C 35.6 ˚F

-0.05616 in -28.8 ˚F 4 ˚C 39.2 ˚F

-0.04914 in -25.2 ˚F 6 ˚C 42.8 ˚F

-0.04212 in -21.6 ˚F 8 ˚C 46.4 ˚F

-0.03510 in -18.0 ˚F 10 ˚C 50.0 ˚F

-0.02808 in -14.4 ˚F 12 ˚C 53.6 ˚F

-0.02106 in -10.8 ˚F 14 ˚C 57.2 ˚F

-0.01404 in -7.2 ˚F 16 ˚C 60.8 ˚F

-0.00702 in -3.6 ˚F 18 ˚C 64.4 ˚F

0.00000 in 0.0 ˚F 20 ˚C 68.0 ˚F

0.00702 in 3.6 ˚F 22 ˚C 71.6 ˚F

0.01404 in 7.2 ˚F 24 ˚C 75.2 ˚F

0.02106 in 10.8 ˚F 26 ˚C 78.8 ˚F

0.02808 in 14.4 ˚F 28 ˚C 82.4 ˚F

0.03510 in 18.0 ˚F 30 ˚C 86.0 ˚F

0.04212 in 21.6 ˚F 32 ˚C 89.6 ˚F

0.04914 in 25.2 ˚F 34 ˚C 93.2 ˚F

0.05616 in 28.8 ˚F 36 ˚C 96.8 ˚F

0.06318 in 32.4 ˚F 38 ˚C 100.4 ˚F

0.07020 in 36.0 ˚F 40 ˚C 104.0 ˚F

0.07722 in 39.6 ˚F 42 ˚C 107.6 ˚F

0.08424 in 43.2 ˚F 44 ˚C 111.2 ˚F

0.09126 in 46.8 ˚F 46 ˚C 114.8 ˚F

0.09828 in 50.4 ˚F 48 ˚C 118.4 ˚F

0.10530 in 54.0 ˚F 50 ˚C 122.0 ˚F

0.11232 in 57.6 ˚F 52 ˚C 125.6 ˚F

Assignment #4 cont.

9

Earth

Assignment #5 – Adjust Cable & Buckle

Design to work on Mars

Weight=Mass*Gravity Acceleration

Modified Buckle design for Mars WeightDiameter (d) 1/2*d π*r^2 10000/CSA 10000/CSA 3750/CSA 3750/CSA

Buckle Size (in) Radius ( r ) CSA (in^2) Stress (PSI) Stress (Mpa) Stress (PSI) Stress (Mpa)

1/16 0.031 3.068E-3 3.259E+6 22.473E+3 1.222E+6 8.428E+3

1/8 0.063 12.272E-3 814.873E+3 5.618E+3 305.577E+3 2.107E+3

3/16 0.094 27.612E-3 362.166E+3 2.497E+3 135.812E+3 936.392E+0

1/4 0.125 49.087E-3 203.718E+3 1.405E+3 76.394E+3 526.721E+0

5/16 0.156 76.699E-3 130.380E+3 898.937E+0 48.892E+3 337.101E+0

3/8 0.188 110.447E-3 90.541E+3 624.262E+0 33.953E+3 234.098E+0

7/16 0.219 150.330E-3 66.520E+3 458.641E+0 24.945E+3 171.990E+0

1/2 0.250 196.350E-3 50.930E+3 351.147E+0 19.099E+3 131.680E+0

9/16 0.281 248.505E-3 40.241E+3 277.450E+0 15.090E+3 104.044E+0

Modified Cable design for Mars WeightCable Design EARTH MARS

Mass (truck)= 310.85 lbs(m) 310.85 lbs(m)

Grav. Acc.= 32.17 ft/s2

12.06375 ft/s2

Weight 10,000 lbs 3750 lbs

Cable Length 25 ft 25 ft

Allowable Stretch 10.00% 10.00%

Max. Length 27.5 ft 27.5 ft

Strain 0.1 0.1

CSA 3.333E-03 in2

1.250E-03 in2

Min. Diameter (in) CSA 65.147E-3 39.894E-3

Best Diameter to use 1/8 in 1/16 in

10

Assignment #6 - Figure Cost to get

Cable/Buckle Assembly into Orbit

• Figure weight of Cable and Buckle Assembly

• Figure possible shipping methods and cost to ship weight

• Comb through Design and Process for Errors

11

Weight for Shipping Cost to Mars

Weight = Volume*Density

http://www.azom.com/article.aspx?ArticleID=6130 For 1045 Steel Density

Auto Cad for Volume of buckle

Cable & Buckle Design Earth Units Mars Units

Mass (truck)= 310.85 lbs(mass) 310.85 lbs(mass)

Grav. Acc.(@45°)= 32.17 ft/s2

12.06375 ft/s2

Weight 10000 lbs 3750.00 lbs

1 psi = 0.006894757 megapascals

Cyclic Operations= 100.0E+3

1045 Density= 0.284 lbs/in^3 0.1065 lbs/in^3

Buckle Inner Dia.= 0.6352 in^2 0.2481 in^2

Buckle Outer Dia.= 2.9917 in^2 1.1686 in^2

Buckle Area (Front)= 2.3565 in^2 0.9205 in^2

Buckle Volume= 462.698E-3 in^3 70.601E-3 in^3

Buckle Weight (on earth)= 131.406E-3 lbs. 20.051E-3 lbs.

Cable CSA= 12.272E-3 in 3.068E-3 in

Cable Weight (on earth)= 1.046E+0 lbs. 261.390E-3 lbs.

Combo Weight (on earth)= 1.177E+0 lbs. 281.441E-3 lbs.

Combo Weight (on Mars)= 441.363E-3 lbs. 105.540E-3 lbs.

12

BuckleVolume = Front Area*CSA

Subtract Inner Area from Outer Area to get Total Front Area.

13

Shipping Cost

• 1/16in Cable

• Found weight using Volume and Density

• Found Price per pound for 5 different rockets

14

Shipping Cost

15

• Weight of Cable and Buckle

combined

– Cost for Low Earth Orbit (LEO)

Weight 1.177E+00

Rocket types Cost per lbs

Falcon 9 v 1.1 $ 4,109.00

DNEPR $ 3,784.00

Ariane 5 $ 10,476.00

Delta IV $ 13,072.00

Atlas V $ 13,182.00

Cost

Falcon 9 v 1.1 $ 4,836.29

DNEPR $ 4,453.77

Ariane 5 $ 12,330.25

Delta IV $ 15,385.74

Atlas V $ 15,515.21

Assignment #7 – Mars Temperature

16

Reference Temperature (To )= 68˚F 20˚C

Temperature Range = -225˚F - 70˚F (Temp can be as low as -225˚F at poles and high as 70˚F at equator in summer.)

α (Steel) = 6.5E-06

Original Length = 300 in 25 ft

ΔL ΔT Tempf ˚C Tempf ˚F

-0.61425 in -315.0 ˚F -155 ˚C -247.0 ˚F

-0.59670 in -306.0 ˚F -150 ˚C -238.0 ˚F

-0.57915 in -297.0 ˚F -145 ˚C -229.0 ˚F

-0.56160 in -288.0 ˚F -140 ˚C -220.0 ˚F

-0.54405 in -279.0 ˚F -135 ˚C -211.0 ˚F

-0.52650 in -270.0 ˚F -130 ˚C -202.0 ˚F

-0.50895 in -261.0 ˚F -125 ˚C -193.0 ˚F

-0.49140 in -252.0 ˚F -120 ˚C -184.0 ˚F

-0.47385 in -243.0 ˚F -115 ˚C -175.0 ˚F

-0.45630 in -234.0 ˚F -110 ˚C -166.0 ˚F

-0.43875 in -225.0 ˚F -105 ˚C -157.0 ˚F

-0.42120 in -216.0 ˚F -100 ˚C -148.0 ˚F

-0.40365 in -207.0 ˚F -95 ˚C -139.0 ˚F

-0.38610 in -198.0 ˚F -90 ˚C -130.0 ˚F

-0.36855 in -189.0 ˚F -85 ˚C -121.0 ˚F

-0.35100 in -180.0 ˚F -80 ˚C -112.0 ˚F

-0.33345 in -171.0 ˚F -75 ˚C -103.0 ˚F

-0.31590 in -162.0 ˚F -70 ˚C -94.0 ˚F

-0.29835 in -153.0 ˚F -65 ˚C -85.0 ˚F

-0.28080 in -144.0 ˚F -60 ˚C -76.0 ˚F

-0.26325 in -135.0 ˚F -55 ˚C -67.0 ˚F

-0.24570 in -126.0 ˚F -50 ˚C -58.0 ˚F

-0.22815 in -117.0 ˚F -45 ˚C -49.0 ˚F

-0.21060 in -108.0 ˚F -40 ˚C -40.0 ˚F

-0.05265 in -27.0 ˚F 5 ˚C 41.0 ˚F

-0.04914 in -25.2 ˚F 6 ˚C 42.8 ˚F

-0.04563 in -23.4 ˚F 7 ˚C 44.6 ˚F

-0.04212 in -21.6 ˚F 8 ˚C 46.4 ˚F

-0.03861 in -19.8 ˚F 9 ˚C 48.2 ˚F

-0.03510 in -18.0 ˚F 10 ˚C 50.0 ˚F

-0.03159 in -16.2 ˚F 11 ˚C 51.8 ˚F

-0.02808 in -14.4 ˚F 12 ˚C 53.6 ˚F

-0.02457 in -12.6 ˚F 13 ˚C 55.4 ˚F

-0.02106 in -10.8 ˚F 14 ˚C 57.2 ˚F

-0.01755 in -9.0 ˚F 15 ˚C 59.0 ˚F

-0.01404 in -7.2 ˚F 16 ˚C 60.8 ˚F

-0.01053 in -5.4 ˚F 17 ˚C 62.6 ˚F

-0.00702 in -3.6 ˚F 18 ˚C 64.4 ˚F

-0.00351 in -1.8 ˚F 19 ˚C 66.2 ˚F

0.00000 in 0.0 ˚F 20 ˚C 68.0 ˚F

0.00351 in 1.8 ˚F 21 ˚C 69.8 ˚F

0.00386 in 2.0 ˚F 21.1 ˚C 70.0 ˚F

0.00702 in 3.6 ˚F 22 ˚C 71.6 ˚F

0.01053 in 5.4 ˚F 23 ˚C 73.4 ˚F

0.01404 in 7.2 ˚F 24 ˚C 75.2 ˚F

0.01755 in 9.0 ˚F 25 ˚C 77.0 ˚F

0.02106 in 10.8 ˚F 26 ˚C 78.8 ˚F

0.02457 in 12.6 ˚F 27 ˚C 80.6 ˚F

Assignment #7 cont.

17

Mars

Mars Temperature Issue

18

Ductile to Brittle Transition (DBTT)

This problem deals with the fact as the temperature gets colder, the material (1045 Steel) gets

more brittle to the point where it can’t hold a load without breaking.

- 1045 Steel is ~.45% Carbon

( 1 Joule (J) is .74 ft*lbs of Force or 100 (J) is 74 ft*lbs)

*Pulled graph from Steel_Metallurgy_Ohio-State.pdf

Mars Temperature Solution

19

We decided to use a slightly different steel material called A353 Type 1. This type of steel is

used in cryogenics and can handle temperatures down to -196 ˚C. As you can see it contains

Nickel and Silicon along with less Carbon:

1045 Steel A353 Type 1

Carbon - .43 - .50 % 0.13%

Manganese - .60 - .90 % 0.90%

Phosphorous - 0.04% 0.35%

Sulfur - 0.05% 0.35%

Silicon - - .15 - .40 %

Nickel - - 8.5 - 9.5 %

Components of Steel

A353 Type 1 at 70˚F (21˚C) = 27 x 106

psi

at -320˚F (-196˚C) = 30 x 106

psi

1045 Steel 30 x 106

psi

Modulus of Elasticity

From what we have found, A 353 Type 1 Steel

should work both on Mars and Earth.

Info on A353 Type 1 Steel was used from ArcelorMittal 9 percent nickel.pdf